Scope Process Controls

The Protuner Alliance consists of global leaders in integrated process control system analysis and loop tuning. We have over a century of combined experience in providing customers with process control system optimisation techniques, and the tools and training needed to apply them. In field testing of thousands of control loops in plants worldwide, we have helped our customers optimise their installed regulatory control systems, greatly increasing product quality, reducing downtime and increasing bottom line profits.

The Protuner Alliance provides products, service, training and support worldwide. The Protuner field proven open and closed loop testing procedures minimise process disturbances, yet records the necessary time domain data for complete analysis of the installed system. Analysis of the test data identifies control equipment problems that need to be addressed, the interactive dynamics, feedforward or decoupling tuning parameters, and optimum P, PI, and PID tuning for each loop for various gain margin, phase margin, and damping factor specifications.

Experience has shown that using the Protuner will reduce by more than 80% the time required to manually tune loops by trial and error. It is also a proven fact that the Protuner removes much of the guess work out of troubleshooting dynamic problems and is easier to use than even the rule of thumb techniques. Whether your current system utilises pneumatics, analogue, single loop, PLC, or DCS based control, we can provide the solutions to optimise the dynamic performance of your currently installed control system.

“Using the Protuner will reduce by more than 80% the time required to manually tune loops by trial and error”

“Techmation is improving the regulatory control systems operation”

Process plants around the world continue to feel more competitive pressures along with an ever increasing demand for lower unit costs, higher quality, and increased profitability, while still having to comply with ever tighter regulatory standards on emissions. To help meet these goals, regulatory control systems are installed to control the hundreds, and sometimes thousands of individual variables relating to safety, productivity, and efficiency

Our experience has found the following conditions in typical process plants:

30% of the controllers are typically operating in manual
65% of the controllers are poorly tuned or de-tuned to mask control related problems
50% of the control valve actuators and positioners are improperly calibrated
30% of the control valves exhibit excessive hysteresis or stick slip characteristics
Many measurement instruments are improperly calibrated or incorrectly installed
20% of control systems are not properly configured to meet the control system objectives.

We offer state-of-the-art solutions that can identify these problems and optimise the efficiency of your control system, while providing you a solid return on investment

“The productivity and safety of many industries could be doubled in many cases through the exploitation of state of the art instrumentation and control. Similarly, the raw material and energy cost of some processes could be cut in half merely through optimized controls. We have the tools, the knowledge, and the need to strive for these goals.”– Bela G. Liptak, Process Control Instrument Engineers Handbook

A variety of industries are already benefiting from our control system optimisation capabilities:

Power Generation Plants – Optimised regulatory control systems increase boiler efficiencies, reduce emissions, minimise trips, and provide for improved load following capabilities.

Refining – Optimised feedforward and feedback control results in reduced variability in each unit operation, increasing the quality of the control. The Protuner analysis tunes the individual loops and develops the mathematical dynamic models required to extend optimisation to include the entire plant. No APC project should proceed until the regulatory layer of controls is fully tuned and optimised.

Mining and Metals – Optimised control systems provide for more efficient grinding circuits and furnace temperature control in many plants, substantially reducing energy costs and increasing yields. A system analysis typically reveals problem areas before they result in a shutdown and costly repairs.

Pulp and Paper – Optimised regulatory control systems have proven to reduce variability, improve quality and increase bottom line profits.

Chemical and Petrochemical – Tuning the regulatory controls for ramp and hold on batch reactors reduces batch time, saves energy and increases throughput and product quality.

Heating, Ventilating and Air Conditioning (HVAC) – Protuner testing and optimisation of installed energy management systems has proven that 80% of the energy saving can be achieved through the optimisation of the regulatory controller in the system.

Dairy Processing Plants – Protuner testing of large scale milk powder plants have consistently yielded improved throughput, reduced energy and faster start-ups.

The Protuner Alliance Companies:

Our alliance offers worldwide expertise so please don’t hesitate to contact one of our representatives:

Region: Asia Pacific Region

Organisation: Scope Process Controls Pty Ltd

Contact: Graham Jefferson

Email: graham.jefferson@scopepc.com

Website: www.scopepc.com

Region: North and South America

Organisation: Techmation Inc.

Contact: David Ender

Email: davidender@protuner.com

Website: www.protuner.com